Molded block



MOLDED BLOCK Y Filed May 14, 1931 2 SheetsSheet 1 www y' a@ Off@ I Patented Aug. 15, 1933 PATENT OFFICE MOLDED BLOCK Peter J. Maul, Detroit, Mich., and Martin Hoffman', Chicago, Ill.

Application May 14, 1931. Serial No. 537,426 6 claims.A (C1. 72-s5 The invention relates to molded blocks, and is particularly adapted to be embodied in concrete blocks, etc., employed in building construction, fences, lamp-posts, monuments, or the like. 5 One form of the invention comprises a block which preferably .consists of a body portion formed from a mixture of cementitious material and an aggregate, the aggregate beingpreferably porous burned shale which has a cellular strucl) ture. One surface of the block is entirely covered by a sheet of metal which has rearwardly extending flanges that have portions embedded in the body portion of the'block. Secured to the inner surface of the sheet metal are a plurality of fastening and re-enforcing devices which have portions embedded in 'the body Yportion 'of the block. .The fastening and re-enforcing devices are' secured to the sheet metal by an adhesive substance, preferably asphalt.V

The fastening and re-enforcing devices are preferably formed from metal. When they are secured to the sheet metal facing ofthe block by adhesive, as described above, it is not necessary to weld or rivet them to the sheet metal and, therefore, the sheet metal is not distorted or discoiored. The block presents a pleasing appearance as the sheet metal may` be oxidized if it is so desired, or it may be made from some metal which does not tarnish when 'it is sub- @ther advantages of the invention will become apparent as the following detailed description progresses, reference being hadto the a'c- 45. companying drawings, wherein:

Figure 1 is a perspective View of a block which embodies the invention; Fig. 2 is a section taken on line 2--2 of Fig. 1; Fira@ is afragmentary perspective view of a fastening and re-enforcing device employed in the block shown in Figs. 1 and 2, the 'fastening and rte-enforcing devices being shown in connection with a portion Aof the sheet metal facing which forms part of the block shown'in Figs. 1 and 2; Fig. 4 is a section taken. through a mold and material such as stainless steel or Allegheny illustrates a preferred method of producing the blocks shown in Figs.v1 and 2;

Fig. 5 is a perspective view of a block embodying another form of the invention; l

Fig. 6 is a section taken on line 6--6-0f Fig. 5; 60

Fig. 7 is a perspective view of a block. which embodies still another form of the invention;

Fig. 8 is a fragmentary section taken on line 8 8 of Fig. 7 and Fig. 9 is a perspective view of a re-enforcing 65 and fastening device forming part of the block shown in Fig/ls. 7 and 8. I 1

Referring for the present to Figs. 1-- to 3, inclusive, wherein a preferred embodiment ofthe invention is illustrated, the reference character 10 designates, generally, thebody portion of the block, which body portion 10 has one of its surfaces 11 entirely' covered by a sheet metal `panel 12.

The body portion 10 may'be made of any suit- 75 able plastic material, but is usually formed Afrom concrete. In the preferred embodiment of the invention, the body portion 10 comprises a mixture of cementitious material and an aggregate which is preferably a burned porous shale hav- S0 ing a cellular structure. A body portion formed of these materials is relatively light in weight and is also highly fire proof as the aggregate or shale does not calcine when subjected to high temperatures.

As best shown in Fig. 2, the sheet metal'panel 12 has integral rearwardly extending flanges 13 along all of its edges, the ends of the flanges 13 being bent inwardly to provide flanges 14 which are embodied in the body portion 10.

Embedded in the body portion lo are fastening and re-enforcing devices 2o which are preferably secured to the sheet metal panel 12 by anadhesive substance. The adhesive substance is preferably asphalt. It will be noted that a coating 2i of asphalt covers substantially the entire inner sinface of the sheet metal panel 12.

The re-enforcing members 20 are preferably formed from sheet metal and are preferably formed to provide apertured portions 22 adapted 100. to be embedded in the body portion, the apertureol portions 22 having outwardly extending iianges 23 formed integral therewith and adapted to bev embedded in the coating 21.

invention. As shown, a mold 25 is provided and the sheet metal panel 12 is preferably placed face down in the bottom of the mold. The layer 21 of asphalt is then poured upon the inner lsurface of the sheet metal panel 12. In one embodiment of the invention, the asphalt is heated and applied in a' semi-liquid state. Inanother embodiment of the invention a preparation, known as'emulsified asphalt, is employed, the emulsied asphalt being usually a mixture of asphalt and` a thinner. This mixture may be applied to the inner surface of the panel 12 while cold.

After the layer 21 of asphalt has been poured into the panel 12 to provide the coating, the reenforcing members 20 are inserted in the panel and are pressed down into the coating so that the flanges 23 become embedded therein. 'Ihen after the coating 21 has set or hardened, the plastic material is poured into the mold to form the body portion 10. After the plastic material has set the completed block may be removed from the mold.

Another form of the invention is illustrated inFigs. 5 and 6. The'block shown in Figs. 5 and v6 has a body portion 10a, which is preferably identical in construction with the body portion l0 described above, the body portion 10a being provided on one face with a sheet metal panel 12a, which is identical with the sheet metal panel 12. The inner surface' of the sheet metal panel 12ais provided with a coating 21a of adhesive material, preferably asphalt. A plurality of reenforcing and fastening devices 22a are secured to the inner surface of the sheet metal panel 12a by the coating 21a and have portions ernbeded in the body portion 10a. It will be noted that the re-enforcing members 22a are substanstantially identical in construction with the reenforcing members 22, but are arranged diagonally of the sheet metal 12a instead of longitudinally thereof.

Still another form of the invention is illustrated in Figs. '7, 8 and 9, wherein a block is 'shown comprising a body portion 10b, a sheet ,flanges 30 with inturned ends 31, the flanges 30 and the ends 31 being embedded in the portion 10b entering the mold or casting process. The fastening andre-enforcing devices 22h are partially embedded in the coating 2lb which adheres thereto and also to the inner surface of the sheet metal 12b so that spaced portions of the sheet metal are securely fastened to the body Yportion. This tends to prevent buckling of the sheet metal when it is subjected to changes in temperature.

As set forth above, a particular object of the invention is that the fastening and re-enforcing members secure the central portions of the' sheet metal to the concrete in such manner that they tend to prevent concrete in such manner that they metal when it is subjected to changes in temperature. The fastening and re-enforcing devices are secured to the sheet metal in such manner that it is not necessary to rivet or weld them thereto. The exposed surface of the sheet metal is then left unmarred.

One advantage of the invention is that the back While we have shown and described certainl embodiments of our invention, it is to be. understood that it is capable of many modifications. Changes, therefore, lin the construction and arrangement may be made without departing from ing a body portion formed from plastic material, a

sheet metal panel covering a surface of the block, and fastening means secured to the sheet metal by adhesive and having portions embedded in the body portion.

2. A block of the character described comprising a body portion formed from plastic'material, a sheet metal panel having flanges embedded in the body portion, a coating of adhesive material `on the inner surface of the sheet metal panel, and

a fastening device secured to the sheet metal by said coating and having a portion embedded in said body portion.

3. A'block of the character described comprising a body portion formed from concrete, a sheet metal member covering one surface of the block, and fastening devices secured to said sheet metal. by adhesive and having a portion embedded in said body portion.

4. A block'of the character described comprising a body portion formed from plastic material, a sh'eet metal panel covering a surface of the body portion, and means re-enforcing said sheet metal, said re-enforcing vmeans comprising a member secured to said sheet metal by adhesive.

5. A block of the character described comprising a body portion formed from plastic material, a sheet metal panel covering a surface of the body portion, and means re-enforcing said sheet metal, said re-enforcing means comprising a member secured to said sheet metal by asphalt.

6. vA block of thevcharacter described comprising a body portion formed of plastic material, a sheet metal panel covering a surface of the block, a coatingof adhesive material between said sheet metal panel and said surface, and metallic fastening devices embedded in said body portion and said coating of adhesive material.

PETER J. MAUL. MARTIN HOFFMAN. 

